Apparatus and method for reclaiming contaminated material

ABSTRACT

The invention provides a method and apparatus of removing contaminants such as salts, hydrocarbon, chemicals, minerals, and metals from materials such as sand, soil, gravel, drill cuttings, and other solids, and reclaiming contaminants and materials for reuse. The invention is scalable in size and capability, economic to construct and operate and reliable in operation and performance. The invention slurries contaminated material with a solution. Transports the slurried material throughout a hydraulic chamber, where the contaminants become more associated with the solution than the material. The invention then separates the processed material and contaminated solution into unique reclaimed components.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This application claims the benefit of Provisional Application No. 61/706,895, filed Sep. 28, 2012. This invention relates to the handling of waste material and the field of environmental reclamation of waste material. More specifically, the invention comprises a method and apparatus of removing contaminants such as salts, hydrocarbon, chemicals, minerals, and metals from materials such as sand, soil, gravel, drill cuttings, and other solids, and reclaiming contaminants and materials for reuse.

2. Description of the Related Art

Contaminated materials are a byproduct of Oil and Gas Exploration-Completion-Production-Refining-Transportation, Agriculture, Manufacturing, Construction, Mining, Excavation and other activities. There are numerous devices that attempt to clean contaminated materials. Examples of devices can be found in U.S. Pat. Nos. 4,462,416, 4,546,783, 7,404,903, 8,100,198. Due to the performance, reliability, cost to purchase and operate these devices they are seldom used in industry. Instead, contaminated materials are generally handled through stock piling, transferring to a permitted disposal sites, burial, dilution, dispersion or other methods. Thus, as each day passes, the amount of contaminated material on the earth increases. The present invention provides an efficient, economic, reliability option to remove the contaminants from the materials, reducing the volume of waste and reclaiming the majority of the material for reuse. In addition to making the material ready for reuse, in many instances, once removed from the material, the contaminant can be reclaimed to a useful and valuable product as well. Reducing contaminated material is a desirable outcome for all communities. The need for an affordable, efficient reclamation processes and devices exits.

SUMMARY OF THE INVENTION

The invention provides an apparatus and method for removing salts, hydrocarbon, chemicals, minerals, metals and other contaminants from sand, clay, shale, soil, drill cuttings, gravel and other materials. The invention provides a scalable, efficient, economic process that can be set up as a permanent facility or as a mobile skid mounted unit.

In one aspect, the invention is a method for removing contaminants comprising oils, salts, chemicals, minerals from materials comprising of sand, clay, shale, soil, drill cuttings, gravel. The inventive method comprises the steps of:

-   -   a. transferring the contaminated material to a feed mechanism;     -   b. feeding the contaminated material into a slurry device;     -   c. slurring the contaminated material with a solution, which         solution has been designed to efficiently remove the contaminant         from the material;     -   d. transferring the slurred material to a hydraulic chamber,         allowing the slurred material to flow throughout the hydraulic         chamber, wherein the interaction between the contaminated         material and the solution, and the vigorous flowing movement of         the slurred material causes some, most or substantially all of         the contaminant to become more associated with the solution then         the material, the first hydraulic chamber may be in fluid         communication with subsequent hydraulic chamber(s) having a         similar shape and process as the initial hydraulic chamber;

In another aspect, the invention is a method for reclaiming material and contaminants where sand, clay, shale, soil, drill cuttings, gravel, and other materials are contaminated with salts, hydrocarbon, chemicals, minerals, metals and other contaminants. The inventive method comprises the steps of:

-   -   a. providing a slurry device being supplied with contaminated         material and solution;     -   b. providing a hydraulic chamber in fluid contact with the         slurry device;     -   c. slurring the contaminated material with a solution, which         solution has been designed to efficiently remove the contaminant         from the material;     -   d. transferring the slurred material to a hydraulic chamber,         allowing the slurred material to flow throughout the hydraulic         chamber, wherein the interaction between the contaminated         material and the solution, and the vigorous movement of the         slurred material causes the contaminant to become more         associated with the solution then the material, the first         hydraulic chamber may be in fluid communication with subsequent         chamber(s) having a similar shape and process as the initial         hydraulic chamber;     -   e. transferring the material, contaminants and solution from the         hydraulic chamber to the separation chamber.     -   f. separating the slurry into material, contaminants and         solution     -   g. collecting the reclaimed material and reclaimed contaminants         and solution in separate holding containers as reclaimed         components.

In another aspect, the invention is an apparatus for removing contaminants from materials. The inventive apparatus includes a feed mechanism in communication with a slurry device which is in fluid communication with a hydraulic chamber which is in fluid communication with a separation chamber. The feed mechanism is suitable for providing contaminated material into a slurry device wherein the contaminated material is combined with a solution and allowed to flow throughout a hydraulic chamber, wherein the contaminants become more associated with the solution than the material, continuing from the hydraulic chamber into a separation chamber suitable for separating the material from the contaminants and solution.

In another aspect, the invention is an apparatus for reclaiming materials and contaminants. The inventive apparatus includes a feed mechanism in communication with a slurry device which is in fluid communication with a hydraulic chamber which is in fluid communication with a separation chamber. The feed mechanism is suitable for providing contaminated material into a slurry device wherein the contaminated material is combined with a solution and allowed to flow throughout a hydraulic chamber, wherein the contaminants become more associated with the solution than the material, continuing from the hydraulic chamber into a separation chamber suitable for separating the material, the contaminants and the solution into components and holding the components in unique containers as reclaimed material and contaminants.

Numerous objects and advantages of the invention will become apparent as the following detailed description of the preferred embodiments is read in conjunction with the drawings which illustrate such embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts a schematic of a material and contaminant reclamation system.

FIG. 2. depicts a schematic of the Hydraulic Chamber configured with turbulators and a nozzle system.

DETAILED DESCRIPTION OF THE INVENTION

As used herein, the term “material” refers to sand, clay, shale, soil, drill cuttings, gravel, and other solids in singular or plurality. The term “contaminate” comprises salts, hydrocarbons, chemicals, minerals, metals and other items in singular or plurality. The term “contaminated material” refers to a solution, compound, or mix comprising material in singular or plurality and contaminate in singular or plurality dissolved, coated, bonded, reacted thereon. The term “solution” refers to a liquid designed to be best suited for the process of removing the contaminant from the material. The term “slurred material” refers to a combination of contaminated material and solution. The term “contaminated solution” refers to a mix of contaminants that have been removed from the material, and the Solution 11.

Concept of Operations

The depiction in FIG. 1 provides the concept of operations for a notional system providing contaminated material from sources comprising drilling operations, completion operations, production operations, transportation, refining, storage of oil and natural gas, agriculture, factories, refineries, mining, excavation, construction, spills, leaks, naturally occurring, etc.

In the concept of operations for the notional system, earthen material, granular to drill cutting in size, soaked and infused with contaminants, comprising hydrocarbon and chlorides, is the contaminated material 10. Contaminated material 10 is communicated from the source of the contamination to a holding container 101 which is located either at the source site or at a remote facility.

FIG. 1 depicts Contaminated Material 10 being communicated from Holding Container 101 to Feed Mechanism 400. Feed Mechanism 400 further communicating the Contaminated Material 10 to the Slurry Device 500, where the contaminated material 10 is combined with a solution 11. In the notional system, Pump 304 used to pressurize the solution 11 may be a single pump or a plurality of pumps, and, the Slurry Device 500 may be present in singular or plurality.

As an alternative to using solution 11 at ambient temperature, bypass 301 is utilized to communicate Solution 11 to Heater 302, where Solution 11 is heated to a desired temperature prior to being communicated to Slurry Device 500. The implementation of a heater at this point in the process will be dictated by the physical properties of the Contaminated Material 10 and the specific conditions of the actual site.

Alternatively, the Contaminated Material 10 is pretreated prior to prior to being communicated to the Feed mechanism 400. The pretreatment may comprise steps such as the removal of debris, sorting, sizing, immersing, wetting, and heating for the purpose of improving the performance of the process. The pretreatment of Contaminated Material 10 will be dictated by the physical properties of the Contaminated Material 10 and the specific conditions of the actual site.

At this point in the process, the contaminated material 10 has been combined with a solution 11 to form a slurry. This slurry is a combination of material, contaminants and solution, and is now referred to as Slurred Material 12.

The Slurry Device 500 is in fluid communication with the Hydraulic Chamber 600. The Hydraulic Chamber 600 may be in fluid communication with subsequent hydraulic chambers, in singular or plurality, having similar shape and process as the initial Hydraulic Chamber 600. The Hydraulic Chamber 600 and subsequent hydraulic chambers provide an area where the Slurred Material 12 moves throughout, wherein the interaction between Contaminated Material 10 and Solution 11, and the vigorous movement of the Slurred Material 12 causes the contaminant to become more associated with the solution then the material.

Alternatively, the Hydraulic Chamber 600 performance may be enhanced through the addition of Turbulator surfaces 602 on the interior of the Hydraulic Chamber 600 which impart additional motion onto the Slurred Material 12. This motion enhances the separation of the contaminant from the material.

Alternatively, the Hydraulic Chamber 600 performance may be enhanced through the addition of a pressurized Nozzle System 603. This pressurized Nozzle System 603 is comprised of a Nozzel 603, in singular or a plurality of nozzles that hydraulically acts on the Slurred Material 12. The Nozzle 603 may comprise a variety of design types, such as, orifice type, shaped orifice type, surface impingement type, pressure swirl spray type, compound nozzle type, etc.

The Nozzle System 603 and Turbulator 602 can be added to the Hydraulic Chamber separately, or concurrently, as they independently perform their function.

Alternatively, Hydraulic Chamber 600 may be in fluid contact with Pump 604 between the Hydraulic Chamber 600 and subsequent hydraulic chambers. Pump 604 serves a multiple purposes, comprising; (1) to pressurize the Slurred Material 12 into subsequent Hydraulic Chambers 600, (2) to impart a shearing and agitating action on the Slurred Material 12, and (3) to increase the surface area of the material by breaking up the material into smaller sized particles.

Alternatively, Hydraulic Chamber 600 may be in fluid contact with Pump 604 between the Hydraulic Chamber 600 and the Separation Chamber 700. Pump 604 serves a multiple purposes comprising; (1) to pressurize the slurry into the Separation Chamber 700, (2) to impart a shearing and agitating action on the Slurred Material 12, and (3) to increase the surface area of the material by breaking up the material into smaller sized particles.

The Separation Chamber 700 acts on the Slurred Material 12, dividing it into components comprising Material 13, Processed Solution 16, and Processed Contaminates 15. Material 13 is separated from Slurred Material 12 using a Solid-Liquid Separation Device 701, such as an oilfield shaker, desand-desilter cones, centrifuge, or a combination of these or similar devices.

The material 13 moves from the Separation Chamber 700 to a Material Holding Container 102 and stored as reclaimed material.

In the notional system the mix of Contaminates and Solution 14 is further processed to separate the Processed Contaminants 15 from the Processed Solution 16 using liquid phase separation devices and other technology.

In the best embodiment of the system, Processed Solution 16 is further treated to remove impurities and moved to Processed Solution tank 105 for reuse as Solution 11. The Processed Contaminant 15 moves from the Separation Chamber to Processed Contaminant Tank 106 and stored as reclaimed Contaminants.

Apparatus

While each step of the process can be manually adjusted, the preferred embodiment utilizes a computer process to control and coordinate the rate of Contaminated Material 10 fed into the Slurry Device 500 with the rate of Solution 11 moved by Pump 304 into the Slurry Device 500.

Referring to the Feed Mechanism 400, there are numerous suitable methods of transferring Contaminated Material 10 from the Holding Container 101 to the Slurry Device 500. The most efficient and economical method may vary from facility to facility and will be dictated by the physical properties of the Contaminated Material 100 being processed and the specific site conditions.

Regarding Solution 11. The composition of the Solution 11 should be tailored to the Contaminated Material 10 being processed and the end requirements of the process. Test trials performed by the inventor utilized filtered well water and a mixture of filtered well water and surfactants. Other possible constituents of Solution 11 include alcohols, xylenes, peroxides, hydrocarbons, alkalis, oxidizers, petrochemicals, oleochemicals, etc, including combinations that comprise these and other chemicals, minerals and mixtures.

Referring to the Slurry Device 500, there are numerous suitable methods that can be used to slurry the Solution 11 with the Contaminated Material 10. The best embodiment may vary from facility to facility and will be dictated by the physical properties of the Contaminated Material 10 being processed and the specific site conditions. Slurred Material 12 exits the Slurry Device 500 liquid enough to flow fluidly throughout the Hydraulic Chamber 600. Test trials performed by the inventor were conducted with a venturi type slurry device and a slurry ratio of 1:1 Contaminated Material 10 to Solution 11. The percentage of Solution 11 to Contaminated Material 10 will be dictated by the physical properties of the Contaminated Material 10 being processed.

FIGS. 1,2 depicts an embodiment where the Hydraulic Chamber 600 is cylindrical in shape. As tested, the cylindrical shape provided efficient movement of the Slurred Material throughout the Hydraulic Chamber. It is noted for the purpose of this document, similar results can be achieved using other shapes for the Hydraulic Chamber 600, such as U shaped channel, V shaped channel, etc, so as long as the shape of the chamber promotes a flowing movement of Slurred Material 12.

Referring to FIG. 1, the inventive apparatus is depicted with a single Hydraulic Chamber 600. Given specific site requirements and conditions the apparatus may contain a plurality of Hydraulic Chambers 600, connected in series or parallel, which are similar in shape and process to the initial Hydraulic Chamber 600. Hydraulic Chambers 600 in parallel will increase throughput volume. Hydraulic Chambers 600 in series will increase performance of the process. If Hydraulic Chambers 600 are connected in series there will be Pump 604 located between the Hydraulic Chambers 600. Pump 604 serves a multiple purposes comprising; (1) to pressurize the Slurry Material 12 into subsequent Hydraulic Chambers 600, (2) to impart a shearing and agitating action on the Slurred Material 12, and (3) to increase the surface area of the material by breaking up the material into smaller sized particles.

FIG. 1 depicts one embodiment of the Hydraulic Chamber 600 where the chamber provides for interaction between the Contaminated Material 10 and Solution 11, now Slurred Material 12, wherein the interaction between the contaminated material and the solution, and the vigorous movement of the slurred material causes the contaminant to become more associated with the solution then the material. FIG. 2 depicts another embodiment of the Hydraulic Chamber 600 where Turbulators 602, in singular or a plurality, are added throughout the length and width of the Hydraulic Chamber 600 to impart a mixing and agitating motion to the slurred material 12. For the purpose of an example, the motion imparted by the Turbulator 602 on the Slurred Material 12 is similar to that of rapids in a river. This added motion enhances the removal of the contaminant from the material.

FIG. 2 depicts another embodiment of the Hydraulic Chamber 600 where a pressurized Nozzle System 603 is added to the Hydraulic Chamber 600. The addition of the Nozzle System 603 serves to assist in moving the Slurred Material 12 throughout the Hydraulic Chamber 600 and to enhance the performance of the process by the increased shearing and agitation imparted on the Contaminated Material 10 carried in the Slurred Material 12. The increased shearing and agitation assists in the removal of the contaminant from the material.

The Nozzle System 603 is comprised of a single or preferably a plurality of Nozzles 603. The Nozzle 603 design may comprises a variety of types, such as, orifice type, shaped orifice type, surface impingement type, pressure swirl spray type, compound nozzle type, etc. The best embodiment will be dictated by the physical properties of the Contaminated Material 10 and the actual site conditions.

Regarding FIGS. 2, Nozzles 603 are positioned around the Hydraulic Section 601 and disposed therethrough. Preferably, a plurality of Nozzles 60311 are disposed on the Hydraulic Chamber 600. The actual position of Nozzle 603 will be dictated by the physical properties of the Contaminated Material 10 and the actual site conditions. In the best embodiment, the Nozzels contain isolation valves controlling flow to each nozzle position, allowing individual nozzles to be serviced without shutting down the working process. During the field trials performed by the inventor, Pump 606 produce a flow of Nozzel Solution 610 at 1,000 pounds per square inch (psi).

Nozzle 603 serves to create an impact force on the Slurred Material 12.

The Separation Chamber 700 is in fluid communication with the Hydraulic Chamber 600.

In one embodiment, the Separation Chamber 700 acts on the Slurred Material 12 exiting the Hydraulic Chamber 600 and serves to separate Material 13 from Contaminated Solution 14.

In another embodiment, Contaminated Solution 14 is further processed by the Separation Chamber 700 to separate Processed Contaminants 15 from the Processed Solution 16 using liquid phase separation devices and other technology.

In another embodiment, Processed Solution 16 is further treated to remove impurities and then moved to Processed Solution tank 105 for reuse as Solution 11. Processed Contaminants 15 move from Separation Chamber 700 to Processed Contaminants Tank 106 and stored as reclaimed Contaminants.

In one embodiment an oilfiled “shaker” 701, in singular or a plurality of shakers, is used to separate the Material 13 from the Contaminated Solution 14.

In another embodiment, oilfield “desander” and “desilter” cones are used to separate the Material 13 from the Contaminated Solution 14.

In another embodiment, a centrifugal cuttings dryer is used to separate the Material 13 from the Contaminated Solution 14.

Depending on the output requirements of the specific application, the Separation Chamber 700 may be comprised of any combination of the Shaker, Desander, Desilter, Centrifigual Cuttings Dryer or other Solid-Liquid, Liquid-Liquid, Solid-Solid separation device.

The Separation Chamber 700 may contain additional equipment to further process Contaminated Solution 14 after it has been separated from the Material 13. In the best embodiment, the output from the additional equipment would be Solution 16 and Processed Contaminants 15. The Processed Solution 16 would be fluidly connected to Holding Containers 105 for reuse or disposal. The Processed Contaminants 15 would be held in Holding Containers 106 for reuse or disposal. 

What is claimed is: I. A METHOD FOR REMOVING CONTAMINANTS FROM MATERIALS
 1. A method for removing contaminants comprising oils, salts, chemicals, minerals, etc. from materials comprising of sand, clay, shale, soil, gravel, drill cuttings, etc. The method comprising: transferring the material to a process feed mechanism; feeding the material into a slurry device; slurring the contaminated material with a solution; transferring the slurred material to a hydraulic chamber; transporting the slurred material throughout the hydraulic chamber, allowing some, most or substantially all of the contaminates on the material to be removed from the material in the hydraulic chamber;
 2. The method of claim 1, further comprising the step of pretreating the contaminated material prior to the feeding mechanism to enhance the contaminant removal process.
 3. The method of claim 1, wherein the step of transporting said slurred material throughout said Hydraulic Chamber, allowing contaminates to be removed from material, is enhanced by the additional of turbulators throughout the Hydraulic Chamber.
 4. The method of claim 1, wherein the step of transporting said slurred material throughout said Hydraulic Chamber, allowing contaminates to be removed from material, is enhanced by the additional of nozzles throughout the Hydraulic Chamber.
 5. The method of claim 1, where the hydraulic chamber is in fluid contact with a separation chamber.
 6. The method of claim 1, further comprising a step of transporting the slurred material from the hydraulic chamber to the separation chamber.
 7. The method of claim 1, where the material of the slurred material is separated from the contaminants and solution of the slurred material in the separation chamber.
 8. The method of claim 7, further comprising the step of processing the contaminants and solution in the separation chamber into unique components;
 9. The method of claim 7, further comprising the step of transporting the reclaimed material and the unique components to holding containers. II. AN APPARATUS FOR RECLAIMING MATERIALS AND CONTAMINANTS
 10. A contaminated material reclamation apparatus comprising: a slurry chamber, and a hydraulic chamber and a separation chamber, said slurry chamber being in fluid communication with said hydraulic chamber being in fluid communication with said separation chamber; a slurry device positioned within said slurry chamber, said slurry device being suitable for combining said solution with said contaminated material, the combination of which forms slurred material; a separation device positioned within said separation chamber, said separation device being suitable for removing material from said slurred material.
 11. The apparatus of claim 10, further comprising a pretreatment chamber capable of preparing said contaminated material for processing through the invention.
 12. The apparatus of claim 10, further comprising a feed mechanism capable of transporting the contaminated material from a holding container to said slurry chamber at the desired rate.
 13. The apparatus of claim 10, further comprising a pressurization system in fluid communication with a solution holding tank and said slurry device, said pressurization system capable of supplying said solution to said slurry device at the desired rate and pressure.
 14. The apparatus of claim 10, further comprising a nozzle positioned within said hydraulic chamber, said nozzle being suitable for injecting nozzle solution into said hydraulic chamber and impacting said slurred material.
 15. The apparatus of claim 10, further comprising a turbulator affixed to the interior wall of said hydraulic chamber, said turbulator being suitable to cause turbulent flow to said slurred material.
 16. The apparatus of claim 10, further comprising a pressurization chamber, said pressurization chamber cable of providing said nozzle with said solution at a desired rate and pressure.
 17. The apparatus of claim 14, further comprising a plurality of nozzles.
 18. The apparatus of claim 15, further comprising a plurality of turblators.
 19. The apparatus of claim 10, further comprising a heating system, said heating system suitable to heat said solution to a calculated temperature.
 20. The apparatus of claim 10, further comprising subsequent separation devices within said separation chamber, said subsequent separation devices are suitable for separating contaminants from solution. 